Boost converter with integrated high power discrete FET and low voltage controller

ABSTRACT

A boost converter for high power and high output voltage applications includes a low voltage controller integrated circuit and a high voltage, vertical, discrete field effect transistor. The low voltage controller integrated circuit and the high voltage, vertical, discrete field effect transistor are packaged together in a single package on a common electrically conductive die pad, wherein the controller IC is attached to the die pad using insulating adhesive and the FET is attached to the die pad using conductive adhesive.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/224,157, filed Sep. 1, 2011, the entire disclosures of which areincorporated herein by reference. U.S. application Ser. No. 13/224,157is a continuation-in-part and claims the priority benefit of U.S.application Ser. No. 12/784,391, filed May 20, 2010 (now U.S. Pat. No.8,207,602), the entire disclosures of which are incorporated herein byreference. U.S. application Ser. No. 12/784,391 application is acontinuation-in-part of and claims the priority benefit of applicationSer. No. 11/761,313, filed on Jun. 11, 2007 (now U.S. Pat. No.7,750,447), the entire disclosures of which are incorporated herein byreference. U.S. application Ser. No. 13/224,157 is also a continuationof and claims the priority benefit of U.S. application Ser. No.11/761,301, filed on Jun. 11, 2007, now U.S. Pat. No. 8,008,897, theentire disclosures of which are incorporated herein by reference.

FIELD OF THE INVENTION

This invention generally relates to boost converters and moreparticularly to high voltage, high power boost converter solutions.

BACKGROUND OF THE INVENTION

Boost converter circuit is used to boost an input voltage to a higheroutput voltage. A boost ratio of ten or more is possible, e.g., inportable display applications. A boost converter may be used, e.g., topower a string of white LED diode for LCD backlight. In such situationsboost converter may be used to convert a five volt input to an outputvoltage of up to 50V. A boost converter generally includes five basiccomponents, namely a power semiconductor switch, a diode, an inductor, acapacitor and a modulation controller.

For high power and high output voltage application, a complementarymetal-oxide-semiconductor (CMOS) boost controller integrated circuit(IC), an external high voltage N-type field effect transistor (NFET),which provides the necessary blocking voltage, and an external senseresistor are conventionally used as shown in a boost converter 100 ofFIG. 1. As shown in FIG. 1, boost converter circuit 100 includes a diepad 102 onto which is mounted a low voltage integrated circuit (IC)containing a controller 104. An external sense resistor R_(s) and anexternal high voltage NFET 106 may be coupled to the controller 104. Thecontroller 104 may be any type of modulation controller, such as apulse-width modulation (PWM) controller. An inductor L may be directlycoupled between the input voltage V_(IN) of the controller 104 and adrain D of the NFET 106 at a switch point denoted LX. An external senseresistor R_(s) may be coupled between a source S of the NFET 106 andground. An external high voltage (HV) Schottky diode D_(Sch), and acapacitor C may be coupled in series between the drain D and the ground.An output voltage V_(OUT) may be obtained at a point between theSchottky diode D_(Sch), and the capacitor C. There may be a voltage dropV_(DIODE) across the Schottky diode. This type of boost convertercircuit 100 may be applied in high voltage, high power applications withlow-side or high-side current sense. Such applications may use anexternal high voltage NFET and an external high power sense resistor atthe high side or low side. The external sense resistor may ease the highvoltage requirement for the controller IC 104. However, the total sizeof the low voltage CMOS IC, the external high power resistor and theexternal high power FET is often larger than is desirable for boardspace sensitive applications such as portable template DVD players,ultra-compact portable personal computers. In addition, the externalsense resistor and the external high power FET increase the total Billof Material (BOM) Cost.

For low power but high output voltage applications, a fully integratedboost converter with CMOS or Bipolar Controller and DMOS or Bipolarboost switch is sometimes used, e.g., as shown in FIG. 2. Similar toboost converter circuit 100 as described above, a boost converter 200may include an inductor L directly coupled to the input voltage V_(IN)and coupled to an output voltage V_(OUT) through an external highvoltage (HV) Schottky diode D_(Sch) and a capacitor C provides smoothingof the output voltage V_(OUT). The boost converter 200 may also includea low voltage controller 204, a high voltage NFET and a high voltagecurrent sense resistor 206, all of which are built on a multi-voltage IC202, which must be high voltage-rated.

For low power but high output voltage applications, a fully integratedBoost Converter may achieve a small form factor. However, the productioncost may be too high due to the custom nature of the high voltage ICprocesses, which require a maximum voltage rating (Vout+Vdiode) dictatedby process limitations.

It is within this context that embodiments of the present inventionarise.

BRIEF DESCRIPTION OF THE DRAWINGS

Objects and advantages of the invention will become apparent uponreading the following detailed description and upon reference to theaccompanying drawings in which:

FIG. 1 is a circuit diagram of a boost converter of the Prior Art.

FIG. 2 is a circuit diagram of another boost converter of Prior Art.

FIG. 3 is a circuit diagram of a boost converter according to a firstembodiment of the present invention.

FIG. 4 is a top view of a boost IC package assembly of the boostconverter of FIG. 8.

FIGS. 5A-5C are circuit diagrams illustrating the boost convertershaving the external sense resistors located either at low-side orhigh-side of the boost converter according to a second embodiment of thepresent invention.

FIGS. 6A-6B are top views of boost IC package assemblies of the boostconverters of FIG. 5A and 5B.

FIG. 7 is a circuit diagram of a boost converter according to a thirdembodiment of the present invention.

FIG. 8 is a top view of a boost IC package assembly of the boostconverter of FIG. 12.

FIG. 9 is a circuit diagram of a boost converter according to a fourthembodiment of the present invention.

FIG. 10 is a top view of a boost IC package assembly of the boostconverter of FIG. 9.

DESCRIPTION OF THE SPECIFIC EMBODIMENTS

Although the following detailed description contains many specificdetails for the purposes of illustration, anyone of ordinary skill inthe art will appreciate that many variations and alterations to thefollowing details are within the scope of the invention. Accordingly,the exemplary embodiments of the invention described below are set forthwithout any loss of generality to, and without imposing limitationsupon, the claimed invention.

According to embodiments of the invention, a low voltage controller maybe co-packaged with a high-voltage vertical discrete FET in ahigh-voltage output booster configuration in a single package.

FIG. 3 is a circuit diagram illustrating a boost converter 300 accordingto an embodiment of the present invention. As shown in FIG. 3, boostconverter 300 includes low voltage controller 306 having an internalcurrent sense device 310 is built on a first die pad 302. The sensedevice 310 may be a resistor or a transistor, e.g., a FET such as ametal-oxide-semiconductor field effect transistor (MOSFET)). By way ofexample, the controller 306 may be a pulse width modulation (PWM)controller, such as a model MAX1771 step-up DC-DC controller from MaximIntegrated Products of Sunnyvale, Calif. Alternatively, the controller306 may be any other type of modulation controller, such as a pulsefrequency modulation controller. The controller 306 may be manufacturedusing a low voltage CMOS process with a rating up to an input voltageV_(IN) only, which may provide better performance, lower powerconsumption, and lower die cost due to efficient layout. Specifically,due to a higher breakdown requirement for high voltage CMOS processes,the lateral spacing of devices and minimum geometry of the devices ismuch higher than for a low voltage CMOS process. A high voltage dualsource vertical discrete FET 308 having sources S1, S2, a drain D and agate G is built on a second die pad 304 is used for an output switch.One source S1 (used for sensing) may be coupled to ground through theinternal current sense device 310. The other source S2 (used for power)may be coupled directly to ground. Examples of vertical FETs and methodof fabricating vertical FETs are described, e.g., is U.S. Pat. Nos.5,126,807, 5,242,845, 5,260,227, 5,578,508 and 6,621,121, all of whichare incorporated herein by reference.

The FET may be characterized by a device size ratio of 1:N. Typically,each device S1, S2 is made up of a number of cells in parallel. The 1:Nsize ratio may be determined from the ratio of the number of cells inone source S1 to the number of cells in the other source S2. The sizeratio may be approximately equivalent to the ratio of current throughthe two devices S1 and S2. The value of N in the ratio will determinethe efficiency of the system and tracking linearity for the sense sourceS1. If N is small, tracking linearity tends to be good but the systemtends to be less efficient because more current is being drawn for thesense device S1. If N is large, the efficiency tends to be good buttracking linearity tends to be reduced because the device mismatchbetween the sense source S1 and power source S2 is too large. For lowpower operation, (e.g., less than about 1 amp) N typically ranges fromabout 300 to about 1000. For high power (e.g., more than about 1 amp), Nis typically between about 1000 and about 3000.

Preferably, the high voltage discrete FET 308 has a bottom Drain D.Commercially available discrete FETs are typically bottom drain FETS.The discrete FET 308 can provide a much higher voltage rating withoutthe penalty of die size and ON resistance. Current sensing for eithermodulation control or discrete FET protection may be accomplished by aDual Source pad layout for the Discrete FET 308, and therefore. In sucha configuration, no additional high voltage device is required forcurrent sensing. An external inductor L may be directly coupled betweenthe input voltage V_(IN) and drain D of the discrete FET 308. Anexternal high voltage (HV) Schottky diode D_(Sch), and a capacitor C maybe coupled in series between the inductor L and ground at a switch pointLX. An output voltage V_(OUT) may be obtained at a point between theSchottky diode D_(Sch) and the capacitor C. There may be a voltage dropV_(DIODE) across the Schottky diode D_(Sch). The HV dual source,vertical discrete FET 308 may have a drain to source voltage (V_(Ds))rating up to (V_(OUT)+V_(DIODE)) and gate to source voltage (V_(GS))rating up to V_(IN).

The controller 306 and discrete FET 308 may be co-packaged on a splitdie pad within a single package to provide a high-voltage, high-powersolution in a compact form factor. By way of example, FIG. 4 is a topview of a boost IC package assembly 400 of the boost converter 300 asdescribed in FIG. 3. As shown in FIG. 4, the low voltage controller 306may be attached to the first die pad 302 with a layer of eitherconductive epoxy or insulating epoxy deposited between the modulationcontroller 306 and the first die pad 302. The dual source, discrete FET308 may be attached on the second die pad 304 with a conductive epoxylayer deposited between the discrete FET 308 and the second pad 304. Thecontroller 306, the discrete FET 308 may be electrically connected toeach other and to leads 404, which are connected to the ground, and toleads 406, which are connected to the inductor, through the bond wires408. The controller 306, discrete FET 308 and bond wires 408 may bepackaged in a plastic package 402.

In alternative embodiments, a low voltage process may be used tofabricate a controller and a high voltage discrete FET with a bottomsource may be used for the output switch. Examples of the structure andmanufacture of bottom source FETs are described, e.g., incommonly-assigned U.S. patent application Ser. Nos. 11/500,810 and11/522,669 both of which are incorporated herein by reference. FIG. 5Ais a circuit diagram of boost converter 500 according to an embodimentof the present invention. The boost converter 500 includes a low voltagecontroller 504 (e.g., a PWM controller) and a bottom source, highvoltage vertical discrete FET 506 having a bottom source S, gate G anddrain D. By way of example, the controller 504 may be a PWM controller.Both the controller 504 and the discrete FET 506 may be built on asingle die pad 502. The boost converter 500 may also include an externalcurrent sense device 508 (e.g., a resistor or transistor, such as aMOSFET) located at a low side of the controller 504 between the source Sand ground. The external current sense device 508 may be characterizedby a resistance R_(s). An external inductor L may be directly coupledbetween the input voltage V_(IN) and drain D of the discrete FET 506. Anexternal high voltage (HV) Schottky diode D_(Sch), and a capacitor C maybe coupled in series between the inductor L and ground. There may be avoltage drop V_(DIODE) across the Schottky diode D_(Sch). An outputvoltage V_(OUT) may be obtained at a point between the Schottky diodeD_(Sch) and the capacitor C. The bottom source, high voltage verticaldiscrete FET 506 may have a drain to source voltage (V_(Ds)) rated to(V_(OUT)+V_(DIODE)) and a low voltage gate to source voltage V_(GS)rated up to V_(IN).

FIG. 5B is a circuit diagram of an alternative boost converter 501 withthe external current sense device 508 located at the high-side of thecontroller 504. In this case the sense resistor 508 may be coupledbetween V_(IN) and an inductor L. An external inductor L may be coupledbetween the external resistor 508 and the drain D. The source S may becoupled directly to ground. An external high voltage (HV) Schottky diodeD_(Sch), and a capacitor C may be coupled in series between the inductorL and ground at a switch point LX. An output voltage V_(OUT) may beobtained at a point between the Schottky diode D_(Sch) and the capacitorC.

FIG. 5C is a circuit diagram of an alternative boost converter 503 thatuses a split die pad. Specifically, the controller 504 may be mounted toa first die pad 502 and the high voltage vertical discrete FET 506 maybe mounted to a second die pad 505. In this example, the controller 504includes an internal current sense device 508 located at the high-sideof the controller 504. By way of example, the internal current sensedevice 508 may be a resistor or a transistor, e.g., a FET such as ametal-oxide-semiconductor field effect transistor (MOSFET). The internalsense device 508 may be coupled between V_(IN) and an external inductorL. The inductor L may be coupled to an external high voltage (HV)Schottky diode D_(Sch), at a switch point LX. A capacitor C may becoupled in series between the Schottky diode D_(Sch) and ground. Anoutput voltage V_(OUT) may be obtained at a point between the Schottkydiode D_(Sch) and the capacitor C.

In the configurations shown in FIG. 5A or FIG. 5B, the controller 504may be co-packaged with the vertical discrete FET 506 on a single diepad. For example, FIG. 6A is a top view of a boost IC package assembly600 containing the boost converter 500. As shown in FIG. 6A, thediscrete FET 506 and the controller 504 may be attached on a single diepad 502 with an insulating epoxy layer 610 deposited between thecontroller 504 and the die pad 502 and a conductive epoxy layer 612deposited between the discrete FET 506 and the single die pad 502. Theinsulating epoxy layer 610 is required to stand off a DC voltagedifferential equivalent to the drop across the external current sensedevice 508. The controller 504 and the discrete FET 506 may beelectrically connected to each other and to the leads 606 and 608through the bond wires 604. The discrete FET 506 may be electricallyconnected to the inductor L through the bond wires 604, and directlyelectrically connected to the external current sense device 508 atground through leads 614. The controller 504 is electrically connectedto the ground through leads 608. The controller 504 and the discrete FET506, which are attached to a single die pad 502, may be packaged in aplastic package 602.

FIG. 6B is a top view of a boost IC package assembly 601 containing theboost converter 501. The structure of the IC package assembly 601 issimilar to the IC package assembly 600, except the discrete FET 506 iselectrically connected to the ground through leads 614 and thecontroller 504 is electrically connected to the external current sensedevice 508 at VIN through the leads 608. In this case, the insulatingepoxy layer 610 has no stand off requirement since voltage differentialis zero, which improves reliability of the boost converter.

The controller 504 may be manufactured using Low Voltage CMOS process,which provides better performance, lower power consumption, and lowerdie cost due to efficient layout. The High Voltage Discrete FET 506 withbottom Source S may be used for the output switch, which provides a muchhigher voltage rating without the penalty of die size and ON resistance.Overall size of the boost converter 500 and 501 may be made compact forHigh Voltage and High Power applications.

FIG. 7 is a circuit diagram of a boost converter 700 according toanother embodiment of the present invention. As shown in FIG. 7, theboost converter 700 may include a low voltage controller 704 (e.g., aPWM controller), a bottom source, high voltage discrete FET 706 and adiscrete current sense device 708 (e.g., a resistor or transistor), allof which are built on a single die pad 702. The controller 704 may bemanufactured using a low voltage CMOS process, which may provide betterperformance, lower power consumption, and lower die cost due toefficient layout. The discrete FET 706 has a bottom source S, gate G anddrain D. The High Voltage Discrete FET 706 with bottom Source may beused for the output switch, which provides a much higher voltage ratingwithout the penalty of die size and ON resistance. The discrete currentsense device 708 may be used to sense the current at the low-side of theboost converter 700 between the bottom source S and ground. By way ofexample, the discrete sense device 708 may be a vertical current flowresistor. As used herein “vertical current flow” means that the resistoris designed so that current flows more or less perpendicular to a planeof a substrate on which the resistor is formed as opposed to flowingalong the plane. The bottom source S and sense resistor 708 areelectrically connected at a junction J.

An external inductor L may be directly coupled between the input voltageVIN and drain D of the discrete FET 706. An external high voltage (HV)Schottky diode D_(Sch), and a capacitor C may be coupled in seriesbetween the inductor L and ground at a switch point LX. There may be avoltage drop V_(DIODE) across the Schottky diode D_(Sch). An outputvoltage V_(OUT) may be obtained at a point between the Schottky diodeD_(Sch) and the capacitor C. The discrete FET 706 may have a drain tosource voltage (VDS) rated to (V_(OUT)+V_(DIODE)) and a gate to sourcevoltage (VGS) rated up to V_(IN).

The overall size of the boost converter 700 may be made compact for HighVoltage and High Power application. For example, FIG. 8 is a top view ofa boost IC package assembly 800 of the boost converter 700. As shown inFIG. 8, the controller 704, the discrete FET 706 and the discrete sensedevice 708 may be located on a single die pad 702. The controller 704may be attached to a part of the single die pad 702 with an insulatingepoxy layer 806 deposited between the controller 704 and the single diepad 702. The discrete FET 706 and the discrete sense device 708 areattached to a different part of the single die pad 702 with one or moreconductive epoxy layers 808 deposited between the discrete FET 704 andthe single die pad 702 and between the discrete sense resistor 708 andthe single die pad 702. The conductive epoxy layer 808 may provideconnections to the bottom source of the discrete FET 704 and thediscrete sense device 708 at the junction J indicated schematically inFIG. 7. Preferably, the insulating epoxy layer 806 is sufficiently thickand/or insulative to be able to stand off a DC voltage differentialequivalent to the drop across the sense resistor 708. The controller704, the discrete FET 706, and the discrete sense resistor 708 may beelectrically connected to each other and to the leads 810 and 812through the bond wires 804. The controller 704, the discrete FET 706,the discrete sense device 708, which are attached on the single die pad702, may be co-packaged in a plastic package 802.

FIG. 9 is a circuit diagram of a boost converter 900 of an embodiment ofthe present invention. As shown in FIG. 9, the boost converter 900 mayinclude first and second die pads 902 and 904. A controller 906 and aninternal sense device 910 (e.g., a resistor or transistor) may be builton the first die pad 902. The controller 906 may be manufactured a UsingLow Voltage CMOS process, which can provide better performance, lowerpower consumption, and lower die cost due to efficient layout. A highvoltage dual source, discrete FET 908 with gates G, sources S1, S2 andbottom drains D1, D2 and a Bottom Anode Schottky Diode (BA-SD) 912 maybe built on the second die pad 904. The High Voltage Discrete FET 908,which may be used as an output switch, provides a much higher voltagerating without the penalty of die size and ON resistance. An inductor Lmay be connected between an input voltage pin VIN of the controller 906and a junction J1. An anode A of the BA-SD 912 may also be connected tothe junction J1. The drains D1, D2 may be coupled together at a junctionJ2. Junctions J1 and J2 may be electrically connected to each other. Theinternal sense resistor 910 may be used to sense the current at thelow-side of the controller 906 between a first bottom source S1 and athird junction J3, which may be connected to ground. The second bottomsource S2 may be coupled directly to the third junction J3. A capacitorC may be coupled between a cathode C_(s) of the Schottky diode 912 andthe third junction J3. There may be a voltage drop V_(DIODE) across theSchottky diode D_(Sch). The discrete FET 908 may have a drain to sourcevoltage (V_(DS)) rating up to (V_(OUT)+V_(DIODE)) and gain to sourcevoltage (V_(GS)) rating up to V_(IN).

FIG. 10 is a top view illustrating a boost IC package assembly 1000 ofthe boost converter 900. As shown in FIG. 10, the controller 906 withthe internal sense device 910 may be attached on the first die pad 902by a conductive or insulating epoxy layer 1006 deposited between thecontroller 906 and the first die pad 902. The discrete FET 908 and theBA-SD 912 may be attached to the second die pad 904 by a conductiveepoxy layer 1008 deposited between the discrete FET 908 and the BA-SD912. The anode A of the BA-SD 912 and the drains D1,D2 may makeelectrical contact to the second die pad 902 via the conductive epoxylayer 1008, thereby providing the equivalent of junctions J1, J2. Thecontroller 906, the discrete FET 908, the BA-SD 912 may be electricallyconnected together or to the leads 1010, 1012 through bond wires 1004.The controller 906 with internal sense resistor 910, the discrete FET908, the BA-SD 912, which are attached on the first and second pad 902,904, are co-packaged on a plastic package 1002.

While the above is a complete description of the preferred embodiment ofthe present invention, it is possible to use various alternatives,modifications and equivalents. Therefore, the scope of the presentinvention should be determined not with reference to the abovedescription but should, instead, be determined with reference to theappended claims, along with their full scope of equivalents. Anyfeature, whether preferred or not, may be combined with any otherfeature, whether preferred or not. In the claims that follow, theindefinite article “A”, or “An” refers to a quantity of one or more ofthe item following the article, except where expressly stated otherwise.The appended claims are not to be interpreted as includingmeans-plus-function limitations, unless such a limitation is explicitlyrecited in a given claim using the phrase “means for.”

What is claimed is:
 1. A boost converter, comprising: a low voltagecontroller integrated circuit (IC); a high voltage, vertical, discretefield effect transistor (FET) having a gate coupled to the low voltagecontroller IC; wherein the low voltage controller IC and the highvoltage, vertical, discrete FET are packaged together in a singlepackage on a common electrically conductive die pad, wherein thecontroller IC is attached to the die pad using insulating adhesive andthe FET is attached to the die pad using conductive adhesive.
 2. Theboost converter of claim 1, wherein the low voltage controllerintegrated circuit includes a pulse-wide modulation (PWM) controller. 3.The boost controller of claim 1, wherein the low voltage controller ICincludes an internal sense device.
 4. The boost controller of claim 1,wherein the internal sense device includes a resistor or transistor. 5.The boost controller of claim 4 wherein the internal sense deviceincludes a field effect transistor.
 6. The boost converter of claim 1wherein the high voltage, vertical, discrete field effect transistor isattached to a die pad using a conductive epoxy.
 7. The boost controllerof claim 6, wherein the low voltage controller IC includes an internalcurrent sense device.
 8. The boost controller of claim 7 wherein theinternal current sense device includes a resistor or transistor.
 9. Theboost controller of claim 7 wherein the internal current sense deviceincludes a field effect transistor.
 10. The boost converter of claim 7further comprising an external high voltage Schottky diode mounted tothe second die pad.
 11. The boost converter of claim 10 wherein theexternal high voltage Schottky diode is a bottom-anode Schottky diodehaving a bottom anode coupled to a drain of the a high voltage,vertical, discrete FET.
 12. The boost converter of claim 11 wherein thebottom anode of the Schottky diode is in electrical contact with thesecond die pad.
 13. The boost converter of claim 11 wherein the highvoltage, vertical, discrete field effect transistor includes a bottomdrain in electrical contact with the second die pad.
 14. The boostconverter of claim 11, wherein the bottom-anode Schottky diode isattached to the second die pad using a conductive epoxy between thebottom anode and the second die pad.
 15. The boost converter of claim 1further comprising an external high voltage Schottky diode having ananode coupled to a drain of the high voltage, vertical, discrete FET.